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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

BOTTLE 1 - Introduction and BOTTLE Overview

The Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE) Consortium aims to develop robust processes to upcycle existing waste plastics and to develop new plastics that are recyclable-by-design, both in direct alignment with DOE's Strategy for Plastics Innovation. We accomplish our work in the BOTTLE Consortium through an organizational framework that includes three primary research tasks, Deconstruction, Upcycling, and Redesign, which are supported by three cross-cutting tasks, Analysis, Characterization, and Modeling, BOTTLE also has tasks focused on Industry Engagement and Diversity, Equity, and Inclusion (DEI). This presentation will review the approach and management structure of BOTTLE, the importance of analysis-guided research, and the key metrics for carbon, economic, energy, and greenhouse gas emissions. In the FY21-FY23 period, BOTTLE has drafted and enacted a comprehensive DEI plan, assembled a world-class Technical Advisory Board (TAB) to provide constructive feedback on our performance, had our first in-person all-hands meeting in summer 2022, and on-boarded and off-boarded research activities based on active project management and analysis. From an impact perspective, BOTTLE researchers have published over 40 peer-reviewed manuscripts (many in leading journals), submitted >30 patent applications, and initiated 6 funds-in industry partnerships.

BIOMASS FUELS↗
DOE OSTI2022

Functional Divergence in a Multi-gene Family Is a Key Evolutionary Innovation for Anaerobic Growth in Saccharomyces cerevisiae

The amplification and diversification of genes into large multi-gene families often mark key evolutionary innovations, but this process often creates genetic redundancy that hinders functional investigations. When the model budding yeast Saccharomyces cerevisiae transitions to anaerobic growth conditions, the cell massively induces the expression of seven serine/threonine-rich anaerobically-induced cell wall mannoproteins (anCWMPs): TIP1, TIR1, TIR2, TIR3, TIR4, DAN1, and DAN4. Here, we show that these genes likely derive evolutionarily from a single ancestral anCWMP locus, which was duplicated and translocated to new genomic contexts several times both prior to and following the budding yeast whole genome duplication (WGD) event. Based on synteny and their phylogeny, we separate the anCWMPs into four gene subfamilies. To resolve prior inconclusive genetic investigations of these genes, we constructed a set of combinatorial deletion mutants to determine their contributions toward anaerobic growth in S. cerevisiae. We found that two genes, TIR1 and TIR3, were together necessary and sufficient for the anCWMP contribution to anaerobic growth. Overexpressing either gene alone was insufficient for anaerobic growth, implying that they encode non-overlapping functional roles in the cell during anaerobic growth. We infer from the phylogeny of the anCWMP genes that these two important genes derive from an ancient duplication that predates the WGD event, whereas the TIR1 subfamily experienced gene family amplification after the WGD event. Taken together, the genetic and molecular evidence suggests that one key anCWMP gene duplication event, several auxiliary gene duplication events, and functional divergence underpin the evolution of anaerobic growth in budding yeasts.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

National Reactor Innovation Center NRC Early Site Permit Roadmap

The National Reactor Innovation Center (NRIC) at Idaho National Laboratory (INL) in Idaho Falls, Idaho, was authorized under the Nuclear Energy Innovation Capabilities Act (Public Law 115–248) to provide private sector technology developers with resources and infrastructure for testing, demonstration, and performance assessment to accelerate deployment of new advanced reactor technology concepts. NRIC’s mission is to enable clean, affordable, reliable energy by supporting U.S. government investments in nuclear energy research, development, demonstration, and commercialization of new nuclear energy systems. It intends to provide existing facilities and other undeveloped and previously developed sites at INL to advanced reactor vendors for prototype technology testing and deployment. Some of these demonstration projects may be subject to DOE authorization, while other projects may require approval by the U.S. Nuclear Regulatory Commission (NRC) prior to construction and operation. NRIC and INL are considering whether to pursue one or more ESPs to help facilitate new reactor deployment at the INL Site. An ESP would allow early investment in licensing infrastructure in advance of a reactor design being ready to deploy. Through the ESPs, NRIC would help reduce the cost and time required to deploy demonstration reactors at the INL Site. This also will allow INL to bring its nuclear and siting experience to the ESP development process allowing for better and more efficient improvements and utilization of the Site. A preapproved ESP at INL will also remove the uncertainty of NRC siting approvals from the demonstration project proponents, who may not be well positioned to complete the analyses in a timely manner. The purpose of this NRIC ESP roadmap is to provide rigor and understanding needed for INL and DOE decision-makers to make data-informed decisions on pursuing NRC ESPs in support of future advanced reactor demonstrations at INL. The roadmap provides a structured method for addressing potential challenges and identifying options for resolution.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

National Reactor Innovation Center NRC Early Site Permit Roadmap

The National Reactor Innovation Center (NRIC) at Idaho National Laboratory (INL) in Idaho Falls, Idaho, was authorized under the Nuclear Energy Innovation Capabilities Act (Public Law 115–248) to provide private sector technology developers with resources and infrastructure for testing, demonstration, and performance assessment to accelerate deployment of new advanced reactor technology concepts. NRIC’s mission is to enable clean, affordable, reliable energy by supporting U.S. government investments in nuclear energy research, development, demonstration, and commercialization of new nuclear energy systems. It intends to provide existing facilities and other undeveloped and previously developed sites at INL to advanced reactor vendors for prototype technology testing and deployment. Some of these demonstration projects may be subject to DOE authorization, while other projects may require approval by the U.S. Nuclear Regulatory Commission (NRC) prior to construction and operation. NRIC and INL are considering whether to pursue one or more ESPs to help facilitate new reactor deployment at the INL Site. An ESP would allow early investment in licensing infrastructure in advance of a reactor design being ready to deploy. Through the ESPs, NRIC would help reduce the cost and time required to deploy demonstration reactors at the INL Site. This also will allow INL to bring its nuclear and siting experience to the ESP development process allowing for better and more efficient improvements and utilization of the Site. A preapproved ESP at INL will also remove the uncertainty of NRC siting approvals from the demonstration project proponents, who may not be well positioned to complete the analyses in a timely manner. The purpose of this NRIC ESP roadmap is to provide rigor and understanding needed for INL and DOE decision-makers to make data-informed decisions on pursuing NRC ESPs in support of future advanced reactor demonstrations at INL. The roadmap provides a structured method for addressing potential challenges and identifying options for resolution.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Protein Assembly by Design

Proteins are nature’s primary building blocks for the construction of sophisticated molecular machines and dynamic materials, ranging from protein complexes such as photosystem II and nitrogenase that drive biogeochemical cycles to cytoskeletal assemblies and muscle fibers for motion. Such natural systems have inspired extensive efforts in the rational design of artificial protein assemblies in the last two decades. As molecular building blocks, proteins are highly complex, in terms of both their three-dimensional structures and chemical compositions. To enable control over the self-assembly of such complex molecules, scientists have devised many creative strategies by combining tools and principles of experimental and computational biophysics, supramolecular chemistry, inorganic chemistry, materials science, and polymer chemistry, among others. Owing to these innovative strategies, what started as a purely structure-building exercise two decades ago has, in short order, led to artificial protein assemblies with unprecedented structures and functions and protein-based materials with unusual properties. Furthermore, our goal in this review is to give an overview of this exciting and highly interdisciplinary area of research, first outlining the design strategies and tools that have been devised for controlling protein self-assembly, then describing the diverse structures of artificial protein assemblies, and finally highlighting the emergent properties and functions of these assemblies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Methods integrating innate and adaptive immune responses in human in vitro immunization assays

Rapid vaccine development and innovative immunotherapeutics are critical in the fight against emerging outbreaks and global pandemic threats, yet the high costs and prolonged timelines for developing new vaccines underscore the urgent need for robust, predictive pre-clinical testing platforms. The rapid down-selection of vaccine candidates and identification of optimal vaccine formulations can be performed using human in vitro immunization (IVI) assays that recapitulate the complex interactions of the innate and adaptive human immune response. In this review, we present a comprehensive evaluation of three key IVI platforms: the whole blood assay (WBA), monocyte-derived dendritic cell (MoDC) assay with dendritic cell-T cell interface assay (DTI), and the microphysiological human tissue construct assay (HTC). The WBA offers a cost-effective and straightforward approach, while the MoDC + DTI system represents the current gold standard for balancing experimental efficiency with immunological complexity. The HTC assay, by mimicking both spatial and temporal aspects of immune interactions, provides enhanced physiological relevance. We discuss the methodological advantages and limitations of each platform, explore their roles in rapid vaccine candidate screening, and propose strategies for integrating these assays with complementary in vivo models. These insights pave the way for refining IVI assays and accelerating the translational pipeline for next-generation vaccines and immunotherapies.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Through the lens of bioenergy crops: advances, bottlenecks, and promises of plant engineering

Advances in engineering of bioenergy crops were driven over the past years by adapting technological breakthroughs and accelerating conventional applications but also exposed intriguing challenges. New tools revealed rich interconnectivity in the exponentially growing and dynamic 'big' omics data' of metabolomes, transcriptomes, and genomes at previously inaccessible magnitude (global, cross-species, meta-) and resolution (single cell). Insights enabled fresh hypotheses and stimulated disciplines such as functional genomics with discovery of broad regulatory networks and their determinants, that is, DNA parts, including promoters, regulatory elements, and transcription factors. Their rational design, assembly into increasingly complex blueprints, and installation into diverse chassis is an existing frontier that may benefit from emerging technologies to address bottlenecks. Interweaving nature-inspired to fully synthetic parts has already allowed building of fine-tuned regulatory circuits, or new-to-nature metabolic routes insulated from the biological context of the chassis species. Similarly, developments and the evolving need for unifying principles in plant transformation and species-agnostic technologies highlight future opportunities for engineering the next generation of bioenergy plants.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Predictive Assessment of the Chemical Composition of Coal Ash in Reserve at U.S. Disposal Sites

In the United States, more than 2 Gt of coal combustion residuals (i.e., coal ash) are stored in hundreds of disposal units. Recent federal regulations mandate the closure or retrofitting of most coal ash impoundments, presenting significant challenges for waste management. These regulatory pressures also present opportunities to reuse coal ash. However, the quality and quantity of discarded coal ash across the U.S. are not well known, even though this information is crucial for spurring its reuse for conventional and new material applications. This study describes a predictive model for the major element composition of coal ash in reserve at disposal sites of major U.S. coal-fired power plants. This model was constructed from coal purchase records of 705 power stations from 1973 to 2022 and was trained on coal ash composition data, showing that coal ash elemental composition is strongly associated with the source of feedstock coal. The model showed regional shifts in the major element contents of ash produced by power plants in the last 50 years, particularly for calcium and iron (expressed as %CaO and %Fe2O3), as power stations changed their source of coal over this time frame. Our approach enables an estimation of chemical composition for ash stored in waste impoundments at individual power stations. Such information can help to delineate the regional market resource potential of supplementary cements for concrete and other material innovations that would utilize coal ash harvested from disposal sites across the U.S.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Understanding Plant Signaling Via Innovations in Probe Delivery and Imaging

The goal of this project was to develop tools for studying plant processes in living tissues. We wanted a method for introducing probes for studying plant processes such that plants could remain intact and imaged iteratively. Towards this end, we successfully optimized carbon nanofibers that we showed could deliver non-permeable signaling probes/biomolecules to plant cells. These were created on a rigid backing and also successfully transferred to a flexible backing to use with curved plant structures. We also built fiber optic microscopes that permit iterative non-destructive fluorescence or light micrographs and created protocols and devices to stabilize plant organs during imaging. These tools were developed in conjunction with research aimed understanding receptor-mediated peptide trafficking and responses relevant to plant cell growth and defense tradeoff. During this project, we designed and built two fiberoptic fluorescence microscopes; (b) designed, fabricated and validated different nanospike designs for delivering probes to plants, including the feasibility of delivering DNA constructs for expression studies; (c) developed fluorescent peptide probes (active and inactive versions of a secreted receptor ligand called phytosulfokine or PSK) and performed mobility tests after application to plants using microscopy; (d) used appropriate genetic plant backgrounds to facilitate PSK trafficking and response mechanisms; (e) determined the transcriptional changes due to PSK-induced signaling related to growth/defense tradeoff; (f) performed experiments showing the growth/defense tradeoff involves repression of specific defense components in response to PSK. This project also involved the training of two PhD students and five Masters students.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Development of New Reactor Core Configuration for Power Uprate - Fuel Reload & Heat Processing Analyses, Core Design, System Safety Assessments, and Fuel Performance Analyses

With the passage of the Infrastructure Investment and Jobs Act in 2021 and the Inflation Reduction Act (IRA) in 2022, the United States stands at a critical juncture for the future of nuclear power. These landmark policies provide significant support for clean energy initiatives, positioning nuclear power as a key component of the nation’s strategy to reduce carbon emissions and achieve energy security. This growing emphasis on nuclear energy is driven by the need for reliable, low-carbon power sources as the country transitions away from fossil fuels. Federal policy, along with increasing state-level support, is encouraging investment in nuclear technology advancements to meet these demands. Building new nuclear power plants (NPPs), however, presents significant challenges due to high costs and long construction timelines. As a result, increasing the power output of existing NPPs through power uprates has emerged as a more feasible and cost-effective strategy. One key area of advancement is the development of accident-tolerant fuel (ATF), such as chromium-coated zirconium alloy cladding, which offers enhanced material performance, enabling power uprates in light water reactors (LWRs). Given the growing demand for nuclear energy fueled by federal policies and state initiatives, it is essential to evaluate the feasibility and benefits of significant power uprates in existing pressurized water reactors (PWRs) using advanced fuel technologies. The introduction of ATF concepts opens new opportunities for safely and economically achieving these power increases. Assessing whether these innovations can support substantial power uprates while maintaining operational safety is crucial to maximizing the potential of the nation’s existing nuclear infrastructure. This project aims to explore how power uprates can be achieved by boosting reactor thermal power output and optimizing reactor core design, while ensuring the safety and economic viability of NPPs. Specifically, it will focus on demonstrating the technical and economic feasibility of power uprates in a PWR using low 5-10% enrichment uranium (LEU+) high burnup (HBU) fuel combined with ATF concepts. In fiscal year 2024 (FY24), the research and development focus on building foundational models and conducting multi-physics performance and safety analyses to support the power uprate. The findings of the study would be shared through LWRS Seasonal Meetings, conferences and workshops with utility companies and researchers. These also serve as a basis for further study of fuel reloading optimization with ATF claddings.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Data for "Enhancing Lipid Production in Plant Cells through Automated High-Throughput Genome Engineering and Phenotyping"

Plant bioengineering is a time-consuming and labor-intensive process with no guarantee of achieving desired traits. Here, we present a fast, automated, scalable, high-throughput pipeline for plant bioengineering (FAST-PB) in maize (Zea mays) and Nicotiana benthamiana. FAST-PB enables genome editing and product characterization by integrating automated biofoundry engineering of callus and protoplast cells with single-cell matrix-assisted laser desorption/ionization mass spectrometry (MALDI-MS). We first demonstrated that FAST-PB could streamline Golden Gate cloning, with the capacity to construct 96 vectors in parallel. Using FAST-PB in protoplasts, we found that PEG2050 increased transfection efficiency by over 45%. For proof-of-concept, we established a reporter-gene-free method for CRISPR editing and phenotyping via mutation of high chlorophyll fluorescence 136. We show that diverse lipids were enhanced up to 6-fold using CRISPR activation of lipid controlling genes. In callus cells, an automated transformation platform was employed to regenerate plants with enhanced lipid traits through introducing multigene cassettes. Lastly, FAST-PB enabled high-throughput single-cell lipid profiling by integrating MALDI-MS with the biofoundry, protoplast, and callus cells, differentiating engineered and unengineered cells using single-cell lipidomics. These innovations massively increase the throughput of synthetic biology, genome editing, and metabolic engineering and change what is possible using single-cell metabolomics in plants.

AI/ML↗
DOE OSTI2025

Enhancing lipid production in plant cells through automated high-throughput genome engineering and phenotyping

Plant bioengineering is a time-consuming and labor-intensive process with no guarantee of achieving desired traits. Here, we present a fast, automated, scalable, high-throughput pipeline for plant bioengineering (FAST-PB) in maize (Zea mays) and Nicotiana benthamiana. FAST-PB enables genome editing and product characterization by integrating automated biofoundry engineering of callus and protoplast cells with single-cell matrix-assisted laser desorption/ionization mass spectrometry (MALDI-MS). We first demonstrated that FAST-PB could streamline Golden Gate cloning, with the capacity to construct 96 vectors in parallel. Using FAST-PB in protoplasts, we found that PEG2050 increased transfection efficiency by over 45%. For proof-of-concept, we established a reporter-gene-free method for CRISPR editing and phenotyping via mutation of high chlorophyll fluorescence 136. We show that diverse lipids were enhanced up to 6-fold using CRISPR activation of lipid controlling genes. In callus cells, an automated transformation platform was employed to regenerate plants with enhanced lipid traits through introducing multigene cassettes. Lastly, FAST-PB enabled high-throughput single-cell lipid profiling by integrating MALDI-MS with the biofoundry, protoplast, and callus cells, differentiating engineered and unengineered cells using single-cell lipidomics. Furthermore, these innovations massively increase the throughput of synthetic biology, genome editing, and metabolic engineering and change what is possible using single-cell metabolomics in plants.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Enabling AI in synthetic biology through Construction File specification

The Construction File (CF) specification establishes a standardized interface for molecular biology operations, laying a foundation for automation and enhanced efficiency in experiment design. It is implemented across three distinct software projects: PyDNA_CF_Simulator, a Python project featuring a ChatGPT plugin for interactive parsing and simulating experiments; ConstructionFileSimulator, a field-tested Java project that showcases 'Experiment' objects expressed as flat files; and C6-Tools, a JavaScript project integrated with Google Sheets via Apps Script, providing a user-friendly interface for authoring and simulation of CF. The CF specification not only standardizes and modularizes molecular biology operations but also promotes collaboration, automation, and reuse, significantly reducing potential errors. The potential integration of CF with artificial intelligence, particularly GPT-4, suggests innovative automation strategies for synthetic biology. While challenges such as token limits, data storage, and biosecurity remain, proposed solutions promise a way forward in harnessing AI for experiment design. This shift from human-driven design to AI-assisted workflows, steered by high-level objectives, charts a potential future path in synthetic biology, envisioning an environment where complexities are managed more effectively.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept

This report summarizes the work performed for the U. S. Department of Energy/National Energy Technology Laboratory (DOE/NETL) under Cooperative Agreement DE-FE0026211 entitled “Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept”. The overall objective of this project was to develop and evaluate a solid oxide fuel cell (SOFC) stack configuration based on a novel prime-surface interconnect design for a broad range of power generation applications. The prime-surface is a one-piece metallic interconnect that incorporates both fuel and oxidant flow fields with peaks on one side of the interconnect serving as flow channels (valleys) on the other side. (One example is the egg-carton shaped interconnect design.) This stack technology has several attractive features including reduced stack weight and volume, decreased performance losses in stacking, improved sealing, versatility in incorporation of different types of cell construction (thin-film cells or sintered cells) and flexibility in gas flow configuration (cross-flow, co-flow or counter-flow). These features lead to lower cost, better performance, and enhanced reliability for the stack. The R&D work of this project focused on demonstrating fabrication, operability and cost effectiveness of the stack design and was conducted by University of California, San Diego (UCSD) in conjunction with OxEon Energy (OxEon). The key technical activities of this project involved prime-surface interconnect design and fabrication development; supported thin-film cell structure development; stack development; stack operation demonstration; and stack cost assessment. The results of these activities are summarized in this report.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

An Educational Program on Concentrated Solar Power and Heliostats for Power Generation and Industrial Processes

The objective of this project was to design and implement a comprehensive educational and applied research program in Concentrated Solar Thermal Power (CSTP) and heliostat technologies at Northeastern University. In alignment with the U.S. Department of Energy's Heliostat Consortium (HelioCon) goals, the project aimed to expand student and public understanding of CSTP systems while simultaneously contributing to workforce development and the broader decarbonization strategy. A particular emphasis was placed on integrating hands-on student design projects and publicly disseminating educational content relevant to CSTP systems. The project addressed a critical gap in renewable energy education: CSTP and heliostats, despite their importance in utility-scale solar energy, are rarely included in standard mechanical engineering programs. This project established new pathways for students to engage with the topic through the creation of a 4-credit graduate/senior elective course, development of five industry-facing short courses, and the inclusion of CSTP-based capstone design projects. Over two academic years, 36 students across six senior design teams developed and tested technologies such as deformable heliostats, beacon-based tracking systems, and solar-powered pyrolizers for biomass-to-biochar conversion. Concurrently, 30 undergraduate and graduate students were enrolled in the new academic course centered around CSTP principles. To ensure the relevance and accessibility of the short course content, the project team engaged with industry professionals, technical policy stakeholders, and potential course participants through structured surveys and informal consultations. Feedback from 28 respondents guided the structure, length, and delivery format of the courses - resulting in a modular design broken into five workshops. The feedback emphasized the need for flexible, asynchronous delivery and practical case studies, particularly in areas such as heliostat control, thermal storage, and solar fuel production. This engagement helped align the courses with the evolving knowledge demands of the renewable energy workforce and ensured that participants from both technical and policy backgrounds could meaningfully benefit from the material. The research and educational activities advanced the understanding of heliostat control systems, optical performance under misalignment, and thermal system integration in solar-driven pyrolysis applications. Methods and designs explored in this project proved to be both technically effective and economically feasible at the lab scale. Prototypes were constructed using commercially available components and custom-fabricated elements, demonstrating that meaningful performance improvements can be achieved with modest material and fabrication costs, supporting the feasibility of student-led research in this field. The public benefit of this project is twofold. First, it cultivates a pipeline of engineers trained to be familiar with CSTP principles, an essential workforce need identified by the Department of Energy for achieving its 2030 cost and deployment targets. Second, it contributes openly accessible educational materials, course content, and experimental frameworks to the broader community, enabling other institutions to adopt or adapt similar programming. Through outreach activities, curriculum integration, and technical exposure, this project contributes to a more informed and capable renewable energy workforce while supporting innovation in heliostat and CSTP system design. A new technical report is being prepared to document the development of the course and its outcomes, with plans to publish it in the ASME Open Access Journal of Engineering to ensure global accessibility, free of cost.

14 SOLAR ENERGY↗
DOE OSTI2024

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Utilities and grid operators worldwide are under significant pressure to incorporate intermittent renewable sources while strategizing on how to maintain the necessary stability and reliability of the grid. The development of a power plant which will be capable of flexible operation to meet the needs of the grid as more intermittent sources like wind and solar energy are incorporated is key to maintain the reliability of the grid. Through the use of innovative and cutting-edge technologies that improve efficiency and reduce carbon emissions, and being small compared to today's conventional utility-scale power plants, the modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. Specifically, the process offers: 1) a modular plant design that allows for better operational flexibility; 2) the utilization of fuel-staging and pressurized oxy-combustion, resulting in smaller plant size, improved plant efficiency, and reduced costs for pollutant and CO2 removal compared to traditional power plants with post-combustion capture technology; and 3) the use of small modular boilers and pollutant removal units that can be constructed off-site leading to reduced capital costs for the plant. WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustor-boiler system and the direct contact cooler. To demonstrate the boiler convective section and to obtain critical data for commercial-scale pressurized boiler design, a simulated convective heat transfer boiler test section was designed and integrated with the combustor (radiant section). A direct contact cooler (DCC) was integrated with the combustor-boiler to demonstrate the dynamic operation of the integrated system and the performance of the DCC, including the efficiency for simultaneous removal of NOx and SOx. This talk will present an update on the evaluation of the critical components for system integration, including heat transfer data from the simulated boiler, scrubbing efficiency for the DCC under different operating conditions, and CFD modeling and validation for burner and boiler development.

Magalhaes, Duarte↗
DOE OSTI2020

Estimation of elastic properties of an additively manufactured lattice using resonant ultrasound spectroscopy

Development of improved approaches in the characterization of additively manufactured structures continues to be a topic of interest for the advanced manufacturing community. This article will investigate an approach using resonant ultrasound spectroscopy (RUS) to determine the effective elastic constants of an orthotropic lattice structure. The evaluation is performed on a cube shaped 316 L stainless steel test specimen, constructed using selective laser melting techniques. The approach uses RUS techniques in conjunction with the assumption that in the frequency regime of interest, the wavelength of the diagnostic ultrasound is greater than the discrete structural features of the unit cell of the lattice; thus, the AM structure can be treated as an anisotropic continuum with effective material properties and symmetry inherited from the unit cell. The RUS analysis estimates the nine elastic coefficients associated with orthotropic sample symmetry, which, in turn, are used to determine the elastic moduli and Poisson ratios. Current results show good agreement between experiments and modeled data. Comparisons to published results are also in good agreement, indicating the potential applicability of this characterization technique for estimating the linear elastic properties of innovative additive manufactured metal lattice structures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Techno-Economic Analysis of Compressed Air Energy Storage and Hydrogen Production from Variable Renewable Energy

This study presents the techno-economic analysis (TEA) results of integrating electrolysis hydrogen (H 2 ) production, compressed air energy storage (CAES), and H 2 -fired combustion turbines in a high variable renewable energy (VRE) market environment. The inconsistent nature of VRE creates challenges for power producers in maintaining a stable electrical grid as it is increasingly utilized. The mission of the National Energy Technology Laboratory (NETL) is driving innovation and delivering energy solutions, and a multiangle approach involving H 2 production, energy storage, and next-level H 2 -fired combustion turbine generator (CTG) technologies could provide one solution for the nation’s growing electrical grid issues with increasing VRE sources. The H 2 production and CAES concept were investigated due to its ability to provide utility-scale H 2 -fueled power generation with large-scale energy storage capabilities. Two facilities with CAES and natural gas-fired CTGs (in McIntosh, Alabama, and Huntorf, Germany) have been operating for decades. In contrast, this study investigates the potential to replace the natural gas fuel with H 2 fuel. This concept has been publicly presented by both Siemens Energy and Bechtel Global Engineering, Construction & Project Management (Bechtel) at two different power generating levels. The CAES and air expansion/combustion turbine power generation in this study are primarily based on the Siemens Energy system (Bailie, Aug. 10-11, 2021) (Scheller, Feb. 21, 2023). The inclusion of a H 2 turboexpander generator is from Bechtel (Gülen, Sep. 6, 2022). A block flow diagram of the proposed process is illustrated in Exhibit ES-1.

08 HYDROGEN↗